SEA-Mate Analyser and Blender

Transcription

1 Bunker Summit Greece 2007 SEA-Mate Analyser and Blender May 11 - Session 6: Under The Spotlight: New Technologies and innovation in the bunker sector 12:10 12:20 Terry Robinson Web: CPHMFTMKT@maersk.com PAGE 1

2 Maersk Fluid Technology - Business & Marketing Plan 2007 (Draft) PAGE 2

3 The Challenge Usage of rotating machinery in marine environments has grown exponentially over the past 30 years there are about 45,000 vessels in operation, ~ 5,800 being Container Vessels Tramp Freighters Liner Freighters Container Vessels Off-shore exploration / production platforms Oil & Gas supply vessels FPSO Crude, Gas and Product Tankers Ever growing fleet of marine vessels providing transportation of goods in a global economy Crew size availability of man-power Ever more complex technologies involved Growing environmental awareness / concerns Rapidly growing costs both capital and operational expense: Daily Running Cost biggest metric on the deep blue seas #1 cost factor = fuel #2 cost factor = lubricants #3 cost factor = maintenance PAGE 3

4 The Challenge Cont.. Heavy Fuel Oil Specification issues include:- Density, Viscosity, TSP, CCR, Flashpoint, Water, H 2 S, cat fines, Sulfur Sulfur content in SECA (Sulfur Emission Control Areas) Operational constraints in waiting for sample results if specifications are marginal. Speed of Bunkering V de-bunkering of out of spec Fuel (i.e. Sulfur marginally higher than 1.5% or cat fines above 80 PPM) Monitoring of filter / Separators to ensure removal of cat-fines Main Engine System Oil Contamination (from Stuffing box) Decreased fuel efficiency with increased contamination. Cylinder Oil (Two Stroke) Need for varying TBN based on HFO Sulfur content i.e. if HFO S=low then waste of BN and possible ring deposits Wear related to Cylinder Feed rates Hydraulic Oils and other Lubricants Base line and wear trending Maersk Fluid Technology, Inc. May 11, 2007 PAGE 4

5 The Solution Optimize use of hydrocarbons on-board / -site equipment: reduce consumption of fuels and lubricants improve the environmental impact optimize lubricant formulation / cost-engineer lubricant performance Introduce tools to enable Predictive Maintenance and Incipient Failure Detection: near real-time analyses of hydrocarbons to assess equipment health apply artificial intelligence to analyze / fingerprint scenarios enable state-of-the-art data communication pathways to enable on- and off-board interpretation, analysis and product procurement: Remote Monitoring & Diagnostics Introduce the SEA-Mate line of products: on-board / -site analyses of elemental concentration in hydrocarbon fluids on-board / -site analyses of water contamination in hydrocarbon fluids on-board / -site analyses of other critical components: sulphur, cat-fines, monomers, asphaltenes, viscosity, density, heat content, etc. On-board/ -site blending of lubricants and fuels as operating conditions and product availability dictate PAGE 5

6 Engine Technology: issues Normal Operation PAGE 6

7 Engine Technology: issues Low BN cylinder oil / High-S fuel PAGE 7

8 Engine Technology: issues high BN cylinder oil / low-s fuel PAGE 8

9 Liner Vessel 101 and then there are all other hydrocarbons that require close monitoring heavy fuel oil ancillary equipment: gear oils, hydraulic fluids, etc. marine distillate fuel TP engine oil bow thruster hydraulic oils stern tube oil ME system oil ME cylinder oil stern thruster hydraulic oils PAGE 9

10 SEA-Mate Analyzer Fast and Simple Elemental Analysis System: Simple, accurate and efficient on-board/-site testing of heavy fuel oil (HFO) before it comes onboard for Sulphur (± 0.01%) and cat-fines down to protection limit in less than 10 minutes. Quality Testing of HFO for waste oils etc. Engine Wear Characteristics of scrape-down samples with the following elements: Calcium, Vanadium, Chromium, Iron, Nickel, Copper, Zinc, Barium, Lead and Phosphorus. Simple-to-understand user interface, which includes use of bar-code reader for logging a) time, b) sample location, c) sample fluid / associated specification for quality control, and d) sample bottle ID, removing errors via manual input Maersk Fluid Technology, Inc. May 11, 2007 PAGE 10

11 SEA-Mate Analyzer Fast and Simple user interface Non destructive testing of samples, Simple bar code system to pair Sample locations with unique sample bottle ID s, Specification limits are pre-assigned to location ID s, Traffic light (Green / Amber / Red) sample results against specifications, Comparative trending of results, Password security with full results and time stamped traceability, Based on open standards communications for future proofing, Possible communications with other onboard systems for comparative trending (engine load, speed, humidity, etc), Enterprise communications protocol for possible business system integration, Artificial intelligence model capability for data processing and pattern matching PAGE 11

12 SEA-Mate Analyzer Status: Gen-II: Demonstration of commercially available system to both internal and external parties has yielded large interest from both OEMs and maintenance specific companies Maersk Oil & Gas, Maersk Contractors, MAN B&W, Wärtsilä, Mitsubishi Heavy Industries, Vestas, and DONG / Energi2 Field Trials: Presently 10 SEA-Mate Gen-II Analyzers installed on-board vessels and a Power Generation Barge in Mindanao with very encouraging results fully updated Gen-III SEA-Mate to be used with Blender trial on Sine Maersk Gen-II SEA-Mate deployed on Power Barge PB-118 to support SEA-Mate BoB-trial. Gen-III: to be included with all Blending-on-board installations includes capability to analyze cat-fines down to 5 ppm for bunkers first prototype to be available by 2Q 2007, vessel trial to begin 3Q 2007 PAGE 12

13 Lab correlation + Gen-3 PAGE 13

14 Optimised Fluid Solutions SEA-Mate Blender SEA-Mate Blender: tool to provide on-board / -site blending of optimized fluids, namely main engine cylinder oil from used system oil to increase operational flexibility and reduce daily running cost blends fluids of widely different physico-chemical characteristics to consistent, high-performance lubricant specifications Delivers tailor-made lubricants to meet the demands of the vessel and fuel Why use used system oil? Constant replenishment of system oil leads to improved system oil condition: Reduces cooling bore deposits Improves main engine bearing lubrication Improves engine efficiency Reduces waste PAGE 14

15 SEA-Mate Blender - Layout Fuel Lubricator Day Tk. Cylinder Oil Emissions Hold. Tk. SEA-Mate Analyser Main Engine SEA-Mate Blender Scavenge Oil Fresh System Oil Used System Oil Additive Sludge Tk. ME Sump Clean Tk. Add. Tk. PAGE 15

16 SEA-Mate Blender - installed PAGE 16

17 SEA-Mate Blender Status SEA-Mate Blender: Presently 2 SEA-Mate blenders installed on-board Sine Maersk and PB-118 power Barge in Mindanao, Philippines In addition, off-board blending continues to be tested on Caroline Maersk MAN B&W evaluation / comparison of commercial cylinder lubricants vis-à-vis blended cylinder oil, prove performance even in part superior to commercial grades Blender re-design to reduce costs, improve reliability, operations and installations to be completed by end of 2006, with prototypes to become available by May 2007 Installation of next generation blenders on A.P. Moller Maersk container fleet to begin Q A second series of trials will investigate the feasibility of blended oil solution to allow running on low and zero sulphur fuels in environmentally sensitive areas PAGE 17

18 SEA-Mate Blender Features Several design options available dependent on requirements SEA-Mate Blender - Key features: Blended oil properties are PLC controlled Mass flow meter or volume flow meter options available Capable of blending range of fluids Base oil feed stream up to o C Additive feed stream up to o C Typical finished fluid for HFO operation *» TBN range 35-80mgKOH/g» Viscosity typically 16.5cSt (figure dependent on feed streams) Volumes up to 2.5m 3 /hour possible Classification bodies approvals ABS approval granted for several Maersk vessels Discussion ongoing with other classification bodies Approval granted on a per vessel basis Pre-Type approval next generation prototypes approved by ABS and Lloyds Register Type approval design in progress * TBN and viscosity range is dependent on feed streams used. For LSFO alternative additive technologies can be introduced PAGE 18

19 OEM Approvals Negotiation with OEM s regarding blended oil specification and approvals underway with the following proposals received: The blender unit must as a minimum fulfil the following requirements for the blended product: o TBN min. 40, ASTM D2896 o Stable TBN (± 2 mgkoh/g), ASTM D2896 o Stable viscosity (± 2%, SAE50), ASTM D445 o Oil stability (no precipitation after one month storage) o No abrasive particles, e.g. sand, dust etc, ICP/XRF measurements o Water: max 0.2%, ASTM D1744 o Flash point: min. 1900C, ASTM D93 o TAN: 0 mgkoh/g, ASTM D664 These properties must be tested in an independent lab, and each test result verified by at least two samples taken at the same time. PAGE 19

20 Thank you! Web: CPHMFTMKT@maersk.com PAGE 20